Insulation blanket having a deposited passivator for industrial insulation applications

Abstract

A passivating flexible insulation blanket positionable about a pipe includes an insulation core, an enclosing fabric, and a non-consumable passivator. The insulation core is substantially hydrophobic and includes a microporous material. The enclosing fabric fully encapsulates the insulation core to form a capsule or pouch about the insulation core. The non-consumable passivator is non-consumable such that there is no appreciable change to a mass of the non-consumable passivator after an extended time of activation. The non-consumable passivator is deposited into the insulation core and has a composition soluble in water. The non-consumable passivator includes a leachable component that leaches from the insulation core and is capable of neutralizing acidic components. The leachable component is water soluble and is capable of reacting with a surface of the pipe to form a protective coating on the pipe to aid in inhibiting corrosion formation on the surface of the pipe.

What is claimed is: 
     
       1. A passivating insulation segment positionable about an insulated structure, wherein the passivating insulation segment comprises:
 an insulation material that is substantially hydrophobic; and 
 a non-consumable passivator that is added to the insulation material, wherein:
 the non-consumable passivator is non-consumable such that there is no appreciable change to a mass of the non-consumable passivator after an extended time of activation; 
 the non-consumable passivator comprises a leachable component that leaches from the insulation material to a surface environment exterior to the insulation material; 
 the leachable component is inorganic and capable of neutralizing acidic components when the leachable component and acidic components come in contact with each other; and 
 the leachable component is water soluble and capable of reacting with a surface of the insulated structure to form a protective coating on the insulated structure that aids in inhibiting corrosion formation on the surface of the insulated structure. 
 
 
     
     
       2. The passivating insulation segment of  claim 1 , wherein the leachable component comprises one or more alkaline components. 
     
     
       3. The passivating insulation segment of  claim 1 , wherein the leachable component compromises high solubility silicate ions. 
     
     
       4. The passivating insulation segment of  claim 1 , wherein the leachable component acts as a pH buffer when exposed to the surface environment exterior to the insulation material. 
     
     
       5. The passivating insulation segment of  claim 1 , wherein the non-consumable passivator comprises at least one high solubility silicate and a carrier, wherein the carrier comprises low solubility silicate ions and metal oxides. 
     
     
       6. The passivating insulation segment of  claim 1 , wherein the leachable component promotes magnetite formation on the surface of the insulated structure when exposed to the surface environment exterior to the insulation material. 
     
     
       7. The passivating insulation segment of  claim 1 , wherein the insulation material comprises entangled fibers. 
     
     
       8. The passivating insulation segment of  claim 7 , wherein the entangled fibers comprise at least one of: glass fibers or mineral wool fibers. 
     
     
       9. The passivating insulation segment of  claim 1 , wherein the passivating insulation segment is rigid. 
     
     
       10. The passivating insulation segment of  claim 1 , wherein the passivating insulation segment is flexible. 
     
     
       11. The passivating insulation segment of  claim 1 , wherein the passivating insulation segment further comprises an opacifier to slow radiant heat passing through the passivating insulation segment. 
     
     
       12. A method of manufacturing an insulation segment positionable about an insulated structure, wherein the method comprises:
 providing an insulation material, wherein the insulation material is substantially hydrophobic; and 
 adding a non-consumable passivator to the insulation material, wherein:
 the non-consumable passivator is non-consumable such that there is no appreciable change to a mass of the non-consumable passivator after an extended time of activation; wherein: 
 the non-consumable passivator comprises a leachable component that is capable of leaching from the insulation material when activated; 
 the leachable component comprises an inorganic material capable of neutralizing acidic components when the leachable component and acidic components come in contact with each other; and 
 the leachable component is water soluble and capable of reacting with a surface of the insulated structure to form a protective coating on the insulated structure that aids in inhibiting corrosion formation on the surface of the insulated structure; 
 
 forming the insulation material into a preformed shape; and 
 setting the insulation material in the preformed shape to form the insulation segment. 
 
     
     
       13. The method of manufacturing the insulation segment of  claim 12 , wherein setting the insulation material in the preformed shape to form the insulation segment comprises drying the insulation material in the preformed shape to solidify the insulation material to form a rigid insulation segment. 
     
     
       14. The method of manufacturing the insulation segment of  claim 12 , wherein the non-consumable passivator added to the insulation material is 10 percent by weight. 
     
     
       15. The method of manufacturing the insulation segment of  claim 12 , wherein the leachable component comprises one or more alkaline components. 
     
     
       16. The method of manufacturing the insulation segment of  claim 12 , wherein the non-consumable passivator comprises high solubility silicate ions and a carrier. 
     
     
       17. The method of manufacturing the insulation segment of  claim 12 , wherein adding the non-consumable passivator to the insulation material comprises mixing the non-consumable passivator in a solid or powder form with the insulation material in a mixing vessel. 
     
     
       18. The method of manufacturing the insulation segment of  claim 12 , wherein adding the non-consumable passivator to the insulation material comprises forming an aqueous solution with the non-consumable passivator. 
     
     
       19. The method of manufacturing the insulation segment of  claim 12 , wherein adding the non-consumable passivator to the insulation material comprises aerosolizing the non-consumable passivator. 
     
     
       20. The method of manufacturing the insulation segment of  claim 12 , wherein forming the insulation material into the preformed shape comprises spraying or aerosolizing the insulation material to form the insulation segment.